NASA Technical Reports Server (NTRS) 20010071155: Integrated Vehicle Health Management for the 2nd Generation RLV Program

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Integrated Vehicle Health
Management for the 2 nd Generation

RLV Program

October 11,2000
Marshal L. Merriam
Ames Research Center

m merriam@mail.arc.nasa.gov (650) 604-4737

I

Integrated Vehicle Health Management

♦ 2 nd Generation RLV Program

♦ 3 rd Generation RLV Program

♦ The NASA X-37 IVHM Flight Experiment

♦ Propulsion and Power IVHM

♦ Integrated Vehicle Health Management (IVHM)
Activity at Kennedy Space Center

♦ IVHM Technology at JPL

♦ Structures IVHM for 3 rd Generation RLVs

♦ IVHM Systems Engineering and Integration

Integrated Vehicle Health Management

Session Overview

Space Launch Initiative Goals

♦ Commercial Convergence - Flying on Privately Owned and
Operated Launch Vehicles

♦ Competition - bringing innovation and new ideas to bear

♦ Assured Access - ensuring alternate means of getting to
space despite launch mishaps

♦ The Ability to Evolve - adding new capabilities affordably as
new mission needs emerge

■

2 nd Generation RLV Program Goals

♦ Safety - Fewer than 1 loss of crew incident every 10,000
flights

♦ Reliability - Fewer than 1 loss of vehicle every 1 ,000 flights

♦ Cost - Less than $1 000/lb payload cost to low earth orbit

Integrated Vehicle Health Management

2 nd Gen Program Goals

Collect, process, and integrate information about the health of a
launch system including the vehicle, subsystems, components,
sensors, and ground support systems to make informed decisions
and take appropriate actions to ensure the success of a mission

Avionics/GN&C

Pr^iuftion

Systems

*Data fusion
•Model-based
controllers
•Autonomous
Software Agents

•Planning and Scheduling
•Maintenance Procedures
•Testing

• Anomaly detection and isolation

• Recovery/Reconfiguration

• Component degradation detection

Airframe

Thermal Protection Systems

The Union of Advanced Hardware and Software -
Providing higher reliability, with greater robustness, at lower costs

Integrated Vehicle Health Management

IVHM

Propulsion/Engine/OMS

♦ Automated Data Analysis

♦ Condition based maintenance

♦ Advanced Real-time Anomaly Detection

♦ Advanced Instrumentation -MEMS, Hi
temp, plum spec, high freq

♦ On-Board Automated Leak detection

Thermal Protection

♦ MEMs Temp/Pressure Sensors for
Overgap Filling

♦ Real-Time Smart TPS Diagnostic SW

Airframe Structure

♦ Flight Fiber Optic (FO) Tunable Lasers

♦ Real-time Dynamic FO Measurements

♦ Acoustic Emission/Acoustic Ultrasound

♦ Advanced low/high temp sensitivity

Crew System

♦ Crew Monitoring/Diagnostic Systems

♦ Human-centered computing (HCC)
Crew Smart Sensor Algorithms

Avionics

♦ Non-intrusive high response
measurements of Pressure, Temp, Strain,
Acceleration

♦ Fiber Optic Network Management SW

♦ Wireless High Speed Data Mgmt

♦ Multi-tasked/cause-effect data mining

♦ Multi-use Smart Sensor Algorithms

♦ Distributed decision-making software

♦ Vehicle and Subsystem MBR Tech

♦ Automated feature recognition

♦ Real-time fault prediction software

♦ Reprogrammable/Reconfigurable FDIR

♦ Automated software V&V technologies.

♦ Auto mission planners/schedulers

Ground System

♦ Advanced Launch/Mission Diagnostics/Prog

♦ Automated ground-based maintenance
planners/schedulers/work order generator

♦ Facility Automated Leak detection Hand-Held
Portable Maintenance Aid HW

♦ Automated TPS/Airframe NDE/NDI

Integrated Vehicle Health Management

Some IVHM Technologies

FY01 FY02 FY03

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Bidder’s Briefing

—

ATP

V

1 IVHM Risk Reduction

Milestones

I

IVHM NASA Unique

IVHM Flight Validation Test Plans

Industry Lead

Commercial
Req'ts Baselined

IVHM Systems
Integration Plan

IVHM System HWIL/SW1L Bench Top

Simulations Initiated Testing Initiated

HWIL/SWIL Subsystem
Testing Initiated

Tasks

Verification Data
Defined

Ground Test
Plan Defined

Flight

Exp'ts

Defined

Qualification IVHM System Sims

Data and Downselected

out-year Plans

Qualification
Data and
Metric
Evaluation

Integrated Vehicle Health Management

Roadmap

Enable Mean Time
To Repair MTTR

improve Automated
Fault Detection
On-Board to 95%

Subsystem Objectives

Tech Challenges

Develop Engine IVHM Systems
improve catastrophic reliability
From 1 in 600 to 1 in 4100

Develop Tank/Fee
improve catastrophic reiiauuuy
From 1 in 5000 to 1 in 15000

1 ^

Develop OMS/RCS IVHM

improve catastrophic reliability

From 1 in TBD to 1 in TBD

*

Approaches (Tasks)

r >

Adv Real-Time

Anomaly

Detection
/

\

Fault Tolerant

Reconfigurable

Controls

On-Board

Information

Fusion

N

/

f >

On-Board
Automated
Leak Detection

V ^

Integrated Vehicle Health Management

Requirements Flowdown (TA-5.1)

round

Propulsion

Output

Formats

Command

Protocol

Domain

Knowledge

Data Formats

nformation

fechnologV/

Required

Inputs

Avion*

Integrated Vehicle Health Management

Interface Definitions TA-5.2

♦ The introduction of IVHM will dramatically increase the
amount of software required. Overall viability of IVHM may
hinge on developing the ability to write and flight certify this
software more cheaply than present practice, but with no
compromise on safety. How can we do this?

• Formal Methods- Provable adherence to standards and
requirements

• Agency Best Practices - Example: Shuttle software team

• Software Health Monitoring - On board monitoring of software
state. Internal consistency checks against test data. Redlines.

• Automated verification strategies. Use of Cardinality.

• Fault Tolerant software.

• Automated software generation environments

Integrated Vehicle Health Management

Software Costs TA-5.3

IVHM Benefit Suite
Identification

Detailed Test Plans
Facilities Requirements !

Integrated Vehicle Health Management

Requirements Definition (TA-5.4)

Integrated Vehicle Health Management

Requirements Verification & Testing (TA-5.4)

FY01

FY02

FY03

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ATP

Bidder’s Briefing

I 1VHM Risk Reduction

//

YX IVHM NASA Unique

IVHM Flight Validation Test Plans

Milestones

Industry Lead

Commercial
Req'ts Baselined

IVHM Systems
Integration Plan

IVHM System HWIL/SWIL Bench Top

Simulations Initiated Testing Initiated

HWIL/SWIL Subsystem
Testing Initiated

Tasks

Verification Data
Defined

Ground Test
Plan Defined

Flight Qualification IVHM System Sims

Exp'ts Data and Downselected

Defined out-year Plans

Qualification
Data and
Metric Eval

Integrated Vehicle Health Management

Roadmap

Technical Area

Name

Phone

2 nd Gen Manager

Bill Kahle

256-544-3225

Propulsion

Jim Snoddy
June Zakrajsek

256 544-4972
216-977-7470

TPS

Carol Carroll

650-604-0267

Systems Engineering

Kevin Flynn
Dave Squires

650-604-4062

650-604-0072

Avionics

Anthony Kelly

256-544-7646

Launch Operations
Mission Operations

Jack Fox
Ron Cobbs

321-867-4413

281-483-5894

Vehicle Power

June Zakrajsek

216-977-7470

Structures

Bob Rogowski

757 864-4990

System IVHM

Tom Gormley

650-604-1831

Flight Planning

Keith Schweikhard

661-276-3411

Integrated Vehicle Health Management

IVHM Interfaces